VACUUM SUBLIMINATION PROCESS FOR FORMING OUTSOLES OF ARTICLES OF FOOTWEAR

Abstract

A method for forming a graphic on an outsole for an article of footwear can include preparing an outsole plate for the outsole for graphic sublimation, the outsole plate comprising a plurality of cleat members that protrude outwardly from a base surface of the outsole plate, and mounting the outsole plate within a tray. The method can further include positioning a printed film comprising a graphic over the outsole plate and the tray and positioning the tray assembly inside a vacuum-sublimation oven. The method can further include selecting a pressure, temperature, and duration for transferring the graphic to the outsole plate based on a type of graphic on the printed film, a texture and material of the outsole plate, and a height difference of cleat members on the outsole plate, and activating the vacuum-sublimation oven to transfer the graphic to the outsole plate at the selected pressure, temperature, and duration.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 63/430,557, filed Dec. 6, 2022, which is incorporated by reference herein in its entirety.

FIELD

This disclosure relates generally to articles of footwear and, in particular, systems and methods for printing onto an outsole of an article of footwear.

BACKGROUND

An article of footwear typically includes two main components: a sole structure and an upper. The sole structure is configured for supporting the wearer's foot and providing cushioning between the wearer's foot and the ground. The sole structure may include an outsole that is adapted to contact the ground. The upper is coupled to the sole structure and is configured for securing the wearer's foot to the sole structure. The outsole can include a rigid plate comprising cleat members protruding outwardly from a base surface of the rigid plate.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of an exemplary article of footwear.

FIG. 2 is a bottom view of an exemplary outsole plate for an article of footwear having a first exemplary graphic disposed thereon.

FIG. 3 is a bottom view of an exemplary outsole plate for an article of footwear having a second exemplary graphic disposed thereon.

FIG. 4 is a flow chart of a method for forming a graphic on an outsole for an article of footwear.

FIG. 5 is schematic of an exemplary vacuum sublimation system.

FIG. 6 illustrates an exemplary computing system for implementing a portion of the disclosed methods.

FIG. 7 is an exemplary printed film comprising a first graphic.

FIG. 8 illustrates pre-heating outsole plates for an article of footwear.

FIG. 9 illustrates cleaning an outsole plate in preparation for forming a graphic on the outsole plate.

FIG. 10 illustrates masking outsole plates prior to transferring a graphic from a printed film onto the outsole plates.

FIG. 11 illustrates positioning outsole plates onto outsole-receiving portions of a tray for insertion into a sublimation oven.

FIG. 12 illustrates positioning the printed film of FIG. 7 over the outsole plates within the tray of FIG. 11.

FIG. 13 illustrates positioning a frame over the printed film and tray of FIG. 12 to seal the printed film over the outsole plates.

FIG. 14 illustrates an exemplary sublimation oven configured to receive a tray-outsole-film assembly, such as the assembly shown in FIG. 13.

FIG. 15 illustrates graphic sublimated outsole plates within the tray, after being removed from the sublimation oven.

FIG. 16 illustrates graphic sublimated outsole plates with the first graphic, following the vacuum sublimation process and removal of the film.

FIG. 17 illustrates positioning an exemplary printed film comprising a second graphic over outsole plates within a tray.

FIG. 18 illustrates positioning a frame over the printed film and tray of FIG. 17 to seal the printed film over the outsole plates.

FIG. 19 illustrates inserting the tray-outsole-film assembly of FIG. 18 into a sublimation oven.

FIG. 20 illustrates graphic sublimated outsole plates with the second graphic, positioned within the tray after being removed from the sublimation oven.

FIG. 21 illustrates removing the frame from the tray of FIG. 20 so that the graphic sublimated outsole plates can be removed from the tray.

DETAILED DESCRIPTION

General Considerations

The systems and methods described herein, and individual components thereof, should not be construed as being limited to the particular uses or systems described herein in any way. Instead, this disclosure is directed toward all novel and non-obvious features and aspects of the various disclosed examples, alone and in various combinations and subcombinations with one another. For example, any features or aspects of the disclosed examples can be used in various combinations and subcombinations with one another, as will be recognized by an ordinarily skilled artisan in the relevant field(s) in view of the information disclosed herein. In addition, the disclosed systems, methods, and components thereof are not limited to any specific aspect or feature or combinations thereof, nor do the disclosed things and methods require that any one or more specific advantages be present or problems be solved.

As used in this application the singular forms “a,” “an,” and “the” include the plural forms unless the context clearly dictates otherwise. Additionally, the term “includes” means “comprises.” Further, the term “coupled” or “secured” encompasses mechanical and chemical couplings, as well as other practical ways of coupling or linking items together, and does not exclude the presence of intermediate elements between the coupled items unless otherwise indicated, such as by referring to elements, or surfaces thereof, being “directly” coupled or secured. Furthermore, as used herein, the term “and/or” means any one item or combination of items in the phrase.

Although the operations of some of the disclosed methods are described in a particular, sequential order for convenient presentation, it should be understood that this manner of description encompasses rearrangement, unless a particular ordering is required by specific language set forth below. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed things and methods can be used in conjunction with other things and methods. Additionally, the description sometimes uses terms like “provide,” “produce,” “determine,” and “select” to describe the disclosed methods. These terms are high-level descriptions of the actual operations that are performed. The actual operations that correspond to these terms will vary depending on the particular implementation and are readily discernible by one of ordinary skill in the art having the benefit of this disclosure.

For purposes of this disclosure, portions of an article of footwear (and the various component parts thereof) may be identified based on regions of the foot located at or near that portion of the article of footwear when the footwear is worn on the properly sized foot. For example, an article of footwear and/or a sole structure may be considered as having a “forefoot region” at the front of the foot, a “midfoot” region at the middle or arch area of the foot, and a “heel region” at the rear of the foot. Footwear and/or sole structures also include a “lateral side” (the “outside” or “little toe side” of the foot) and a “medial side” (the “inside” or “big toe side” of the foot). The forefoot region generally includes portions of the footwear corresponding to the toes and the joints connecting the metatarsals with the phalanges. The midfoot region generally includes portions of the footwear corresponding with the arch area of the foot. The heel region generally corresponds with the rear portions of the foot, including the calcaneus bone. The lateral and medial sides of the footwear extend through the forefoot, midfoot, and heel regions and generally correspond with opposite sides of the footwear (and may be considered as being separated by a central longitudinal axis). These regions and sides are not intended to demarcate precise areas of footwear. Rather, the terms “forefoot region,” “midfoot region,” “heel region,” “lateral side,” and “medial side” are intended to represent general areas of an article of footwear and the various components thereof to aid the in discussion that follows.

For purposes of this disclosure, directional adjectives may be employed which correspond to the illustrated example. For example, the term “longitudinal” as used herein refers to a direction extending a length of an article. In some cases, the longitudinal direction may extend from a forefoot portion to a heel portion of the article. Also, the term “lateral” as used herein refers to a direction extending a width of an article. In other words, the lateral direction may extend between a medial side and a lateral side of an article. Furthermore, the term “vertical” as used herein refers to a direction generally perpendicular to a lateral and longitudinal direction. For example, in cases where an article is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. It will be understood that each of these directional adjectives may be applied to individual components of an article, such as an upper and/or a sole structure.

As used herein, the term “exemplary” means serving as a non-limiting example, instance, or illustration. As used herein, the terms “e.g.,” and “for example,” introduce a list of one or more non-limiting examples, instances, and/or illustrations.

As used herein, the term “sole structure” refers to any combination of materials that provides support for a wearer's foot and bears the surface that is in direct contact with the ground or playing surface, such as, for example, a single sole; a combination of an outsole and an inner sole; a combination of an outsole, a midsole, and an inner sole; and a combination of an outer covering, an outsole, a midsole and an inner sole.

As used herein, the terms “attached” and “coupled” generally mean physically connected or linked, which includes items that are directly attached/coupled and items that are attached/coupled with intermediate elements between the attached/coupled items, unless specifically stated to the contrary.

As used herein, the terms “articles of footwear” or “articles” mean any type of footwear, including, for example, basketball shoes, volleyball shoes, tennis shoes, running shoes, soccer shoes, football shoes, rugby shoes, baseball shoes, sneakers, hiking boots, sandals, socks, etc.

Although the figures may illustrate an article of footwear intended for use on only one foot (e.g., a right foot) of a wearer. One skilled in the art and having the benefit of this disclosure will recognize that a corresponding article of footwear for the other foot (e.g., a left foot) would be a mirror image of the right article of footwear.

Unless explained otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present disclosure, suitable methods and materials are described below. The materials, methods, and examples are illustrative only and not intended to be limiting. Other features of the disclosure are apparent from the detailed description, claims, abstract, and drawings.

The Disclosed Technology

An article of footwear typically includes two main components: a sole structure and an upper. The sole structure is configured for supporting the wearer's foot and providing cushioning between the wearer's foot and the ground. The upper is coupled to the sole structure and forms a foot-receiving cavity. The upper is configured for securing the wearer's foot to the sole structure and/or can protect the wearer's foot.

The sole structure may include an outsole that is adapted to contact the ground. In some examples, the outsole can comprise a relatively rigid plate or portion comprising cleat members (or ground contacting members) that protrude outwardly from a surface of the outsole, such as in a soccer, football, baseball, golf, or hiking shoe (e.g., a cleated shoe).

In some examples, an outsole, or a relatively rigid outsole plate for an outsole comprising one or more cleat members, can include a graphic thereon. However, it can be difficult to adhere a printed graphic (e.g., from a printed film) to a relatively rigid, cleated surface (an outsole or outsole plate comprising protruding cleat members). Further, since cleated outsoles are used in sport shoes that experience highly active use and may penetrate and/or grab onto a ground surface (such as turf, grass, or the like), it is important that a graphic is durable and does not rub or peel off the surface of the outsole or outsole plate.

In some examples, vacuum sublimation can be used to apply a graphic from a printed film onto a relatively flat component. However, cleated outsoles or outsole plates can include surfaces with varying heights, such as higher and lower cleat members that protrude outward and away from a sidewall or base surface of the outsole or outsole plate. Applying a graphic to such a surface using vacuum sublimation can be particularly difficult since a printed film being adhered to the cleated outsole surface is prone to tearing against the protruding cleat members under vacuum. For example, it is difficult to get a printed film to adhere to both a lower base surface of an outsole plate and a higher tip surface of an adjacent cleat member without tearing, especially when the outsole plate has an undulating surface due to cleat members of varying heights and shapes.

Disclosed herein are systems and methods for forming a graphic on a surface of an outsole of an article of footwear using vacuum sublimation. In some examples, the outsole can comprise an outsole plate which comprises one or more cleat members protruding outward from a base surface of the outsole plate. The vacuum sublimation process can comprise printing a graphic onto a flexible film, preparing a pair of outsole plates for an article of footwear, and transferring the graphic from the film to a surface of the outsole plates using a vacuum-sublimation system set to specified temperature, pressure, and time duration parameters that are based on the structure, materials, and/or colors of the outsole plates and/or printed film. In some examples, the surface of the outsole plates is relatively rigid and comprises a plurality of cleat members extending outward from the surface. As a result, a graphic can be formed on outsole plates comprising cleat members.

In some examples, a method for forming a graphic on an outsole for an article of footwear comprises preparing an outsole plate for the outsole for graphic sublimation, the outsole plate comprising a plurality of cleat members that protrude outwardly from a base surface of the outsole plate, and mounting the outsole plate within a tray. The method further comprises positioning a printed film comprising a graphic over the outsole plate and the tray to form a tray assembly and positioning the tray assembly inside a vacuum-sublimation oven. The method further comprises selecting a pressure, temperature, and duration for transferring the graphic on the printed film to the outsole plate based on each of a type of graphic on the printed film, a texture of the outsole plate, a height difference of the cleat members on the outsole plate, and a material of the outsole plate. The method further comprises activating the vacuum-sublimation oven to transfer the graphic on the printed film to the outsole plate at the selected pressure, temperature, and duration such that the graphic is formed over at least a first portion of the base surface and cleat members protruding from the first portion of the base surface.

In some examples, a method for forming a graphic on an outsole for an article of footwear comprises preparing an outsole plate for the outsole for graphic sublimation, the outsole plate comprising a plurality of cleat members that protrude outwardly from a base surface of the outsole plate, and mounting the outsole plate within a tray. The method further comprises positioning a printed film comprising a graphic over the outsole plate and the tray to form a tray assembly and positioning the tray assembly inside a vacuum-sublimation oven, and selecting a temperature from within a range of 110 to 140 degrees Celsius and a cycle time from within a range of 300 to 500 seconds for transferring the graphic on the printed film to the outsole plate. The method further comprises activating the vacuum-sublimation oven to transfer the graphic on the printed film to the outsole plate at the selected temperature and cycle time, and at a pressure of −0.1 MPa such that the graphic is formed over at least a first portion of the base surface and the plurality of cleat members.

In some examples, a vacuum-sublimation system comprises a tray comprising an outsole-mounting portion and a rim disposed above the outsole-mounting portion, wherein the outsole-mounting portion is shaped to receive an outsole plate comprising a plurality of cleat members thereon. The system further comprises a frame configured to fit and seal against the rim and a vacuum-sublimation oven comprising a drawer configured to receive the tray therein and one or more controls for setting a pressure, temperature, and time duration for vacuum-sublimation.

Additional examples of the disclosed technology are described below with reference to the accompanying drawings.

Examples of the Disclosed Technology

FIG. 1 is a side view of an exemplary article of footwear 100. For purposes of reference, the article of footwear 100 can be divided into a forefoot region 102, midfoot region 104, and heel region 106. In addition, the article of footwear 100 can include a lateral side 108 (shown in FIG. 1) and a medial side (opposite the lateral side 108). Both the medial side and the lateral side 108 can extend through the forefoot region 102, midfoot region 104, and heel region 106.

The article of footwear 100 comprises two main components: a sole structure 110 and an upper 112. The upper 112 is coupled to the sole structure 110 so as to form a foot-receiving cavity between the sole structure 110 and the upper 112. For example, the upper 112 may include one or more material elements (for example, textiles, foam, leather, and synthetic leather), which may be stitched, adhesively bonded, molded, or otherwise formed to define an interior void configured to receive a foot. The material elements may be selected and arranged to selectively impart properties such as durability, air-permeability, wear-resistance, flexibility, and comfort. The upper 112 shown in FIG. 1 includes a lacing region 114, which includes apertures 116 (e.g., eyelets) for receiving a lace 118 that can be tightened to close the upper 112 around a foot. The upper 112 may alternatively implement any of a variety of other configurations, materials, and/or closure mechanisms (e.g., straps, etc.). The upper 112 can have a variety of shapes, sizes, and/or designs. For example, in examples where the article of footwear 100 is a running shoe, the upper 112 could be a low top upper. In examples where the article of footwear 100 is a basketball shoe, the upper 112 could be a high top upper that is shaped to provide support on an ankle.

The sole structure 110 can be configured to provide traction for the article of footwear 100. In addition to providing traction, the sole structure 110 may attenuate ground reaction forces when compressed between the foot and the ground during walking, running, or other ambulatory activities. The configuration of the sole structure 110 can vary in different examples to include a variety of conventional or non-conventional structures. The sole structure 110 extends between the upper 112 and the ground when the article of footwear 100 is worn. In different examples, the sole structure 110 can include different components. For example, the sole structure 110 can include an outsole, a midsole, and/or an insole. In some cases, one or more of these components may be optional.

In the example shown in FIG. 1, the sole structure 110 comprises an outsole 120. In some examples, the outsole 120 is coupled directly to the upper 112. In some examples, a midsole can be disposed between the upper 112 and the outsole 120 (e.g., where the midsole is configured to provide cushion).

In some instances, the outsole 120 of the sole structure 110 can be configured according to one or more types of ground surfaces on which outsole 120 can be used. Examples of ground surfaces include, but are not limited to: natural turf, synthetic turf, dirt, natural grass, soft natural grass, as well as other surfaces. In some examples, the outsole 120 can comprise one or more cleat systems comprising a plurality of cleat members. The term “cleat members” as used herein includes any provisions disposed on a sole for increasing traction through friction or penetration of a ground surface. Typically, cleat systems and/or cleat members are configured for football, soccer, baseball or any type of activity that requires increased traction. For examples, the cleat members described herein can be configured to grip and at least partially penetrate the ground surface (such as penetrating dirt, grass, gravel, turf, or the like). In some examples, the article of footwear 100 is a soccer shoe. In other examples, the article of footwear 100 can be a baseball, football, golf shoe, or the like.

The outsole 120 can include one or more cleat systems comprising a plurality of cleat members that extend away from (or protrude outwardly from) the sole structure 110. Generally, cleat systems and/or cleat members may be associated with the outsole 120 in a variety of manners. In some examples, cleat systems and/or cleat members may be integrally formed with the outsole 120.

In some examples, the outsole 120 can comprise a relatively rigid baseplate or outsole plate that extends across all or a majority of a lower surface of the sole structure 110. In some instances, the cleat systems and/or cleat members can be integrally formed with the outsole plate. In some instances, the cleat systems and/or cleat members can be attached to the outsole plate, such as by being screwed into holes within the outsole plate or using another type of fastener or adhesive. In some cases, some cleat systems and/or cleat members may be integrally formed with the outsole 120, while other cleat systems and/or cleat members may be attached to the outsole 120.

As shown in FIG. 1, the outsole 120 comprises an outsole plate 122 which comprises a baseplate 124 and one or more cleat members 126 (which can also be referred to as ground engaging members) extending downward (toward the ground) and away from the baseplate 124. In some examples, the outsole plate 122 can form an entirety of the outsole 120.

The baseplate 124 can be a substantially flat element that supports the foot and serves as a substantially rigid platform from which the cleat members 126 extend. The baseplate 124, although relatively flat, can include various anatomical contours, such as a relatively rounded longitudinal profile, a heel portion and/or forefoot portion that are higher than an arch region, and other anatomical features. In addition, the baseplate 124 can include a bottom surface 128, which can be generally flat, but can have various contours that provide stiffness, strength, and/or traction.

The components of the baseplate 124 may be formed of any of a variety of suitable materials. In some examples the baseplate 124, the cleat members 126, and other elements of the outsole plate 122 can be integrally formed. For example, in some instances, the entirety of the outsole plate 122 can be formed of a single material, forming all parts of the outsole plate 122. In such examples, the outsole plate 122 can be formed all at once in a single molding process, for example, with injection molding.

Different structural properties may be desired for different aspects of the outsole 120 and/or outsole plate 122. Therefore, the structural configuration can be determined such that, even though a common material is used for all portions of the outsole plate 122, for example, the different portions may be stiffer, or more flexible due to different shapes and sizes of the components. For example, the heel and midfoot regions of the baseplate 124 can be formed of a thicker material and/or may include reinforcing features, such as ribs, in order to provide stiffness to these portions of the sole component. Whereas the forefoot region of the baseplate 124 can be formed of a relatively thinner material, in order to provide flexibility to the forefoot region. Greater flexibility in a forefoot region may enable natural flexion of the foot during running or walking and may also enable the sole component to conform to surface irregularities, which may provide additional traction and stability on such surfaces. In addition, the cleat members 126 can be formed with a thicker structure to provide rigidity and strength.

In some examples, different portions of the outsole plate 122 can be formed of different materials. For example, a stiffer material, such as carbon fiber, can be utilized in the heel and/or midfoot regions of the baseplate 124, whereas a more flexible material, such as a thin polyurethane, may be used to form the forefoot region of the baseplate 124. In addition, it may be desirable to utilize a stiffer and/or harder material for the baseplate 124, such as carbon-fiber and/or polyurethane, and softer and more flexible material for the cleat members 126, such as a relatively hard rubber. Accordingly, in some examples, the outsole plate 122 can be formed by multiple molding steps, for example, using a co-molding process. For instance, the baseplate 124 can be pre-molded, and then inserted into a sole component mold, into which the cleat member material may be injected to form the cleat members 126, or portions of the cleat members 126.

The outsole plate 122 of the outsole 120 can be formed of suitable materials for achieving the desired performance attributes. For example, the outsole plate 122 can be formed of any suitable polymer, composite, and/or metal alloy materials. Exemplary such materials may include thermoplastic and thermoset polyurethane (TPU), polyester, nylon, polyether block amide, alloys of polyurethane and acrylonitrile butadiene styrene, carbon fiber, poly-paraphenylene terephthalamide (para-aramid fibers, e.g., Kevlar®), titanium alloys, and/or aluminum alloys. In some examples, the outsole plate 122 can be formed of a composite of two or more materials, such as carbon-fiber and poly-paraphenylene terephthalamide. In some examples, these two materials may be disposed in different portions of the outsole plate 122. Alternatively, or additionally, carbon fibers and poly-paraphenylene terephthalamide fibers may be woven together in the same fabric, which may be laminated to form the outsole plate 122. In some examples, the outsole plate 122 can comprise a fiberglass reinforced polyamide or Pebax. Other suitable materials and composites will be recognized by those having skill in the art.

A variety of arrangements of cleat members 126 across the baseplate 124 are possible. As shown in FIG. 1, the cleat members 126 protrude outward and away from the baseplate 124, toward a ground surface. Additionally, in the example of FIG. 1, a first portion of cleat members 126 are disposed at the forefoot region 102 while a second portion of cleat members 126 are disposed at the heel region 106. In some examples, the cleat members 126 are relatively short in width and spaced apart from one another on the baseplate 124. In some examples, the cleat members 126 are elongated and extend across a larger portion of the baseplate 124.

Additionally, an amount that the cleat members 126 protrude outwardly from the baseplate 125 (e.g., in a vertical direction) can vary. For example, some cleat member 126 can have a larger vertical height (protruding outwardly further) than other cleat members 126 of the outsole 120. In this way, the shape, size, and arrangement of cleat members 126 of the outsole plate 122 can be specified (or selected) based on the intended activity, type of surface to be used on, and/or type of shoe (e.g., soccer, football, golf, hiking, and the like).

For clarity, the following detailed description discusses an exemplary outsole plate for a cleated shoe, such as a soccer shoe, but it should be noted that the present invention could take the form of and/or be used on any article of footwear including, but not limited to: hiking boots, soccer shoes, football shoes, sneakers, rugby shoes, basketball shoes, baseball shoes as well as other kinds of shoes.

FIGS. 2 and 3 show examples of graphic sublimated outsole plates 200 for an outsole of an article of footwear (such as the article of footwear 100 of FIG. 1). In particular, FIG. 2 shows a first pair of graphic sublimated outsole plates comprising outsole plates 200 with a first graphic 202 formed thereon via a vacuum sublimation process (as described further below with reference to FIGS. 4-6 and FIGS. 7-16). FIG. 3 shows a second pair of graphic sublimated outsole plates comprising the outsole plates 200 with a second graphic 204 formed thereon via the vacuum sublimation process (as described further below with reference to FIGS. 4-6 and FIGS. 17-21). The outsole plates 200 of FIGS. 2 and 3 can be coupled to an upper to form an article of footwear, such as the upper 112 shown in FIG. 1. For example, in some instances, the outsole plates 200 of FIG. 2 or 3 can be used in lieu of the outsole plate 122 in FIG. 1.

It should be noted that the outsole plates 200 are exemplary and a variety of outsole plates or outsoles can be used with the sublimation process described herein for forming a graphic on a relatively rigid outsole plate, an outsole, and/or outsole plates comprising cleat members.

As shown in FIGS. 2 and 3, the outsole plates 200 comprise a baseplate 206 (with a base surface that faces the ground when attached to an upper of an article of footwear and worn by a wearer) and a plurality of cleat members 208 protruding outward and away from the baseplate 206. Together, the base surface of the baseplate 206 and the ground-facing surfaces of the cleat members 208 can form a ground-facing surface 216 of the outsole plates 200 (e.g., the surface of the outsole plates 200 that faces and contacts the ground when included in an article of footwear and worn). The outsole plates 200 can be divided into a forefoot region 210, midfoot region 212, and heel region 214 (similar to as described above for the article of footwear 100 in FIG. 1).

The cleat members 208 can comprise cleat members 208 of varying vertical height, wherein the height of the cleat members 208 can be measured from a sidewall 218 of the baseplate 206 to a tip 220 of the cleat members 208. The sidewall 218 can be a portion of the baseplate 206 that interfaces with a remainder of the article of footwear when coupled thereto, such as the upper 112 shown in FIG. 1.

For example, as shown in FIGS. 2 and 3, and also in FIG. 8 (as described further below), the outsole plates 200 can comprise first cleat members 222, second cleat members 224, and third cleat members 226, all having varying heights. In some examples, the heights of the various cleat members can vary within a range of 40-80 mm, 50-75 mm, or 60-70 mm. The outsole plates 200 can further include raised portions, such as raised portions 228 that extend between adjacent cleats (e.g., a second cleat member 224 and a third cleat member 226) which having a smaller height that the cleat members 208 but still protrude outward and away from the baseplate 206.

As such, the ground-facing surface 216 of the outsole plates 200, which receives a graphic thereon, can have differently shaped surfaces with different heights, including varying cleat member heights.

Additionally, the cleat members 208 have different shapes such as conical-shaped, blade-shaped (e.g., the first cleat members 222 and third cleat members 226), chevron or V-shaped (e.g., the second cleat members 224), or the like.

In different examples, the outsole plates 200 can have a different arrangement of cleat members 208 than those shown in FIGS. 2 and 3, such as differently shaped cleat members and/or cleat members with different heights (e.g., smaller or larger) than those described above.

In the example of FIG. 2, the first graphic 202 is applied primarily to the heel region 214 and a portion of the midfoot region 212 and not to the forefoot region 210. In the example of FIG. 3, the second graphic 204 is applied to an entirety of the outsole plates 200, including the forefoot region 210, midfoot region 212, and heel region 214. In some examples, a graphic can be applied to more or less regions of the outsole plates 200 than shown in FIGS. 2 and 3, such as to only the forefoot region 210, only the heel region 214, the forefoot region 210 and the heel region 214, or to one or more selected portions across the forefoot region 210, midfoot region 212, and heel region 214.

As shown in FIGS. 2 and 3 the first graphic 202 and the second graphic 204, respectively are formed over the specified portions of the baseplate 206 and the cleat members 208 extending from the specified portions of the baseplate 206. For example, the first graphic 202 and the second graphic 204 can be easily and effectively applied over the varying surfaces of the baseplate 206 and the cleat members 208. Specifically, as shown in FIG. 3 for example, the second graphic 204 can extend from the surface of the baseplate 206, to a side (or lateral) surface of an adjacent cleat member 208, up and over the tip 220 of the cleat member 208, across an opposite side (or lateral) surface of the cleat member 208 and back to another portion of the surface of the baseplate 206.

In other examples, graphics, such as the first graphic 202 and the second graphic 204 can be formed on differently configured outsole plates or outsoles without cleat members. In this way, the vacuum sublimation method described herein can be applied to a variety of outsoles, outsole plates, and outsoles or outsole plates with cleat members (e.g., cleated outsoles or outsole plates). However, in some examples, the methods described herein can be particularly tailored for relatively rigid outsole plates comprising cleat members have a vertical height. In some examples, the methods described herein can be particularly tailored for outsole plates having cleat members with varying vertical heights (e.g., at least two cleat members having different vertical heights relative to the surface of the sidewall 218 of the baseplate 206).

Turning now to FIG. 4, a method 300 for forming a graphic on an outsole for an article of footwear is shown. In some examples, the method 300 can be a method for transferring a graphic from a printed film to an outsole plate comprising cleat members having a height of at least 60 mm (relative to a sidewall of the baseplate of the outsole plate, as described above with reference to FIGS. 2 and 3). In some examples, the method 300 can be a method for transferring a graphic from a printed film to an outsole plate comprising cleat members having varying heights, such that two or more adjacent cleat members have different heights.

The method 300 can be performed, at least in part, by a vacuum sublimation system, such as the vacuum sublimation system 400 shown in FIG. 5. In some examples, the vacuum sublimation system 400 can comprise a computing system, such as the computing system 402 shown in FIG. 6. As shown in FIG. 5, and described further below, the vacuum sublimation system 400 can further include a printer 404 electronically connected to the computing system 402 (either wirelessly or via a wired connection), which can produce a printed film 406 (a film with a graphic printed thereon).

The vacuum sublimation system 400 can further include a heater 408 configured to receive one or more outsole plates 200 therein for heating to a specified temperature and/or for a specified duration of time. The vacuum sublimation system 400 can further include a tray 410 with jigs and frame, wherein the jigs are configured to receive the outsole plates 200 and the frame is configured to seal the printed film 406 over the outsole plates 200 on the jigs. The assembled outsole plates 200 on the tray 410 with the printed film 406 thereon can then be received within a sublimation oven 412 (e.g., vacuum sublimation oven) that is configured to apply pressure (negative pressure) and/or heat to the assembled outsole plates 200 on the tray 410 with the printed film 406 to transfer the graphic (e.g., the dyes of the graphic) on the printed film 406 to the outsole plates 200.

Generally, a vacuum sublimation process uses heat and pressure to transfer the graphic (or graphic element) from the film to the outsole plates. For example, the sublimation oven 412 can be configured to apply a vacuum (negative pressure) within a chamber of the oven 412, thereby transferring the dye from the printed film to the outsole plates 200 (such as by absorbing the dye into the pores of the outsole plates). Heat from the oven 412 can help to transfer and/or adhere the dye from the printed film onto the outsole plates 200. Further details on exemplary settings for the sublimation oven 412 are described below with reference to the method 300 of FIG. 4. Additionally, a more detailed description of the computing system 402 is provided further below.

Returning to FIG. 4, while the method 300 may be explained below with reference to the examples shown in FIGS. 7-16 (for the first graphic 202) and FIGS. 17-21 (for the second graphic 204), it should be noted that the method 300 can be applied to a variety of outsoles and/or outsole plates (e.g., outsoles or outsole plates having cleat members with different shapes, sizes, and/or arrangements across the outsole plate and/or outsoles or outsole plates having a different overall structure) and a variety of graphics (e.g., graphics having different colors, patterns, or arrangements of the graphic on the outsoles or outsoles plates than that shown in FIGS. 2-3 and 7-21).

The method 300 begins at 302 by preparing a graphic (e.g., a specified or selected graphic selected by a user) and printing the graphic onto a film. Preparing the graphic can include designing the graphic using software, such as a graphic design program, using the computing system 402. In some examples, designing the graphic can include creating a shape and/or pattern for the graphic and/or selecting colors for the graphic within the software program and shaping the graphic such that it will fit over a specified outsole or outsole plate (such as the outsole plates 200). In some examples, the created graphic can include a graphic comprising a specified pattern and/or coloring to be applied to one or more portions of a pair of outsole plates (such as the pair of outsole plates 200 shown in FIG. 2 or 3). Once the computer graphic is created, the graphic can be sent (electronically via a wired or wireless electrical connection) to the printer (e.g., printer 404). The method at 302 can then include printing the graphic onto a film, thereby resulting in a printed film (e.g., the printed film 406 shown in FIG. 5).

The film can comprise a polymeric material, such as a thermoplastic. In some examples, the film comprises polyethylene terephthalate (PET). In some examples, a thickness of the film can be in a range of 0.1 to 0.2 mm or 0.13 to 0.17 mm, or be about 0.15 mm.

In some examples, the printer can utilize a sublimation ink for printing the graphic onto the printed film (and thus the printed graphic can comprise the sublimation ink). The selected sublimation ink can have a specified temperature range and time range for transferring the sublimation ink on the printed film to the outsole plates during the vacuum sublimation process (e.g., inside the sublimation oven, as described further below with reference to the method at 316).

An exemplary printed film 500 comprising the first graphic 202 printed onto a film 502 is shown in FIG. 7. As shown in FIG. 7, the first graphic 202 is split into a first side 504 configured to be positioned over a ground-facing surface 216 of a first outsole plate 200 of a pair of outsole plates (e.g., the right foot outsole plate) and a second side 506 configured to be positioned over a ground-facing surface 216 of a second outsole plate 200 of the pair of outsole plates (e.g., the left foot outsole plate).

As shown in FIG. 7, the first side 504 includes a midfoot portion 508 comprising a first color and a heel portion 510 comprising a second color, where the first and second colors are different, such as red and blue. The second side 506 includes a midfoot portion 512 comprising the second color and a heel portion 510 comprising the first color. For the purposes of illustration, the different cross-hatching in FIGS. 2, 7, 12, 13, 15, and 16 is used to depict the different colors of the graphic (rather than the pattern of the graphic). However, in some examples, the first graphic 202 (or other graphics described herein) could also include various patterns or additional graphic elements (e.g., symbols, patterns, letters, numbers, or the like).

FIG. 17 shows an exemplary printed film 600 comprising the second graphic 204 printed onto a film 602. The second graphic 204 is split into a first side 604 configured to be positioned over a ground-facing surface 216 of a first outsole plate 200 of a pair of outsole plates (e.g., the right foot outsole plate) and a second side 606 configured to be positioned over a ground-facing surface 216 of a second outsole plate 200 of the pair of outsole plates (e.g., the left foot outsole plate).

As shown in FIG. 17, on both the first side 604 and the second side 606, the second graphic 204 comprises a repeating pattern of graphic elements 608 across a majority (or all) of the film 602. Thus, when placed over the pair of outsole plates, the second graphic 204 can cover the forefoot region 210, midfoot region 212, and heel region 214 of the outsole plates 200.

In some examples, the first and second graphics 202 and 204 (or other possible graphics) for the first and second outsole plates 200 can be printed separately onto separate films that are individually placed over the corresponding first and second outsole plates 200 (instead of both printed onto the same film).

As shown in FIG. 4, method 300 can continue from 302 to 304, where it includes preparing the printed film. In some examples, preparing the printed film, such as the printed film 500 (FIG. 7) or the printed film 600 (FIG. 17), can include punching one or more holes along edge portions of the printed film. For example, FIG. 7 shows holes 516 which can be used for positioning the printed film 500 onto the tray containing the jigs and outsole plates, as described further below with reference to the method at 314 and FIG. 12 (and also FIG. 17, for the printed film 600).

In some examples, preparing the printed film can include allowing the printed film to dry or cure for a period of time after printing, before attaching it to the tray containing the jigs with outsole plates mounted thereon.

At 306, method 300 includes pre-heating the outsole plates. Pre-heating the outsole plates can include inserting one or more outsole plates, such as a pair of outsole plates, into a heater (e.g., heater 408 of FIG. 5). As an example, the outsole plates 200 are shown pre-heating in the heater 408 in FIG. 8. Pre-heating the outsole plates can include heating the outsole plates at a predetermined temperature for a predetermined amount of time. In some examples, the heater, such as heater 408 can be a tunnel heater with a conveyer belt where a speed of the belt determines the duration of heating at a set temperature of the heater. Pre-heating the outsole plates can help the dye from the graphics on the printed film adhere better to the outsole plates during the vacuum sublimation process. For example, pre-heating the outsole plates can provide better penetration of the dyes from the printed film into the pores of the outsole plates during the vacuum sublimation process inside the sublimation oven. In this way, pre-heating can allow for increased durability and longevity of the graphic on the graphic sublimated outsole plates.

After pre-heating the outsole plates, the method 300 continues to 308, which includes cleaning the outsole plates. For example, as shown in FIG. 9, cleaning the outsole plates can include brushing the entire or at least the portion of the ground-facing surface 216 of the outsole plates 200 that are configured to receive the printed film thereon with a cleaner or cleaning solution (e.g., using a brush 518, a cloth, or other applicator). In other examples, the cleaning solution can be applied in another way, such as spraying onto the surface of the outsole plates. In some examples, the cleaning solution can comprise methyl ethyl ketone (MEK). In some examples, the cleaning solution can comprise acetone. The cleaning solution can be configured to enable the dye of the graphic on the printed film to effectively transfer to the outsole plates 200 during the vacuum sublimation process described further below.

The method at 308 can further include pre-heating the cleaned outsole plates. Pre-heating the cleaned outsole plates can include inserting the cleaned outsole plates into the heater (e.g., heater 408) for a predetermined temperature and duration, similar to as described above for the method at 306.

In some examples, the cleaning of the outsole plates can be omitted and the method can proceed directly from 306 to 310 or 312, as described below.

At 310, method 300 can optionally include masking the outsole plates. Masking the outsole plates can include covering a portion of the ground-facing surface of the outsole plates (such as a portion of the baseplate 206 and/or cleat members 208) with a covering element. In some examples, the covering element can include tape of one or more widths. For example, as shown in FIG. 10, a portion of the ground-facing surface 216 of the baseplate 206 and cleat members 208 of the outsole plates 200 has been covered with tape 520. Thus, a first portion 522 of the ground-facing surface 216 of the outsole plates 200 is uncovered (and thus exposed) and can receive the graphic from the printed film thereon, while a second portion 524 of the ground-facing surface 216 of the outsole plates 200 (the portion underneath the tape 520) is covered (or “masked) such that the graphic is not transferred to the second portion 524 of the outsole plates 200. The tape, or alternate covering element, can prevent the dye from the graphic from running into and being imprinted on portions of the outsole plates intended to be graphic-free (e.g., the second portion 524 and portions of the outsole plates 200 between the taped portions). In this way, the tape 520, or other covering element, can serve as a barrier or border between graphic-receiving portions and non-graphic receiving portions of the outsole plates 200.

In some examples, instead of tape, the covering element can include a material that is brushed on and that prevents dye from the graphic from being transferred to the covered portion (and adjacent portions between the covered portions) of the outsole plates.

The method at 310 can further include pre-heating the masked outsole plates (e.g., using the heater 408, similar to as described above at 306 and 308).

In some examples, masking the outsole plates at 310 may not be performed, and instead method 300 can continue from 308 to 312.

At 312, method 300 includes positioning the outsole plates onto outsole-receiving or outsole-mounting portions (referred to herein as jigs) of a tray. In some examples, as shown in FIG. 11, the jigs 526 are disposed within (e.g., integrated with or attached to) a base of a tray 528, where the tray 528 has a depth to it such that the jigs 526 are below a top rim 530 of the tray 528. Each jig 526 can be shaped to receive a corresponding outsole plate 200 (e.g., the left or right outsole plate 200). In some examples, each jig 526 can be shaped and sized such that an inner surface (a surface disposed opposite the ground-facing surface 216 and that would face a wearer's foot when included in an article of footwear) of the outsole plate 200 fits over and around the jig 526. In some examples, a contour of the jigs 526 can be shaped to receive the cleat members 208 of the outsole plates 200. In this way, the outsole plates 200 can be held securely on the jigs 526. For purposes of illustration, FIG. 11 shows one outsole plate 200 mounted onto a first jig 526 and a second jig 526 without an outsole plate mounted thereon.

After positioning the outsole plates onto the jigs of the tray, method 300 can continue to 314 which includes positioning the printed film over the outsole plates and positioning the tray-outsole-film assembly into a vacuum-sublimation oven. For example, as illustrated in FIGS. 12 and 17, the method at 314 can include transferring the printed film (printed film 500 in FIG. 12 or printed film 600 in FIG. 17) to the rim 530 of the tray 528, over the outsole plates 200. In some examples, as shown in FIG. 12, the holes 516 of the printed film 500 can be aligned with or positioned over corresponding holes or pegs in the rim 530 of the tray 528 to enable accurate alignment of the printed film over the jigs 526 within the tray 528.

The method at 314 can further include sealing the printed film to the tray with a frame or alternative sealing element. As an example, as shown in FIGS. 13 and 18, a frame 532 can be positioned over the tray 528 and onto the rim 530. Edge portions of the printed film 500 (FIG. 13) or the printed film 600 (FIG. 18) disposed against the rim 530 can then be sandwiched between the rim 530 and the frame 532. In some examples, the frame 532 can be coupled (fastened) to the tray 528 such that the frame 532 seals the printed film to the tray. In this way, the outsole plates 200 can be completely covered and sealed within the tray 528 by the printed film and frame 532.

Positioning the tray-outsole-film assembly into the vacuum-sublimation oven can include inserting, sliding, or positioning the tray-outsole-film assembly (e.g., the assembly 534 shown in FIG. 13 or the assembly 634 shown in FIG. 18) into the sublimation oven 412.

An example of the sublimation oven 412 is shown in FIGS. 14 and 19. As shown in FIGS. 14 and 19, in some examples, the sublimation oven 412 can include a sliding drawer 536 (or insert or platform), where the sliding drawer 536 is configured to receive the tray-outsole-film assembly 534 or 634 therein (as depicted in FIG. 19). The sublimation oven 412 can further include a control panel 538 (FIG. 14) with one or more actuator knobs, buttons, or the like for controlling the operating parameters of the sublimation oven. In some examples, the operating parameters can include a pressure (e.g., negative pressure) setting, temperature setting, and/or duration of time for the vacuum sublimation process.

Once the tray-outsole-film assembly is loaded into the vacuum-sublimation oven, the method 300 continues to 316, which includes activating the vacuum-sublimation oven to transfer the graphic from the printed film to the specified portions of the outsole plates (or outsoles).

Activating the vacuum-sublimation oven at 316 can first include selecting settings for the vacuum sublimation process, wherein the settings can include one or more of a pressure, temperature, and time duration (or “cycle time”). The pressure, temperature, and/or time parameters can be specified based on the type of outsole or outsole plate (material, texture, overall shape, overall size, cleat member shape and size, and/or the like), the color of the outsole or outsole plate, the color(s) and/or size or surface area of the graphic on the printed film, and/or the like.

For example, an outsole having cleat members with larger variations in vertical height can be more difficult to sublimate (due to potential tearing of the film which can cause color inconsistency) than an outsole having cleat members with smaller variations in vertical height, and thus these two different outsoles can have different pressure, temperature, and time duration parameters for the vacuum sublimation process. For example, a higher temperature and/or longer duration for sublimation can be selected as a vertical height difference between one or more cleat members of the cleat members on the outsole plate increases.

In some examples, a film having a solid color graphic (e.g., regions of a solid color), such as the first graphic (FIG. 2), can be more difficult to sublimate than a film having a patterned graphic (e.g., a pattern without solid color in one larger region, such as the second graphic 204 of FIG. 3). As such, a higher temperature and longer cycle time (time for sublimation) can be used for a film with a solid color graphic as compared to a film with a patterned graphic. However, in some instances, a higher temperature and/or cycle time can be used for graphics covering an entirety of the film, rather than only a portion of the film (e.g., a graphic configured to cover only a portion of the outsole, such as only the heel and midfoot, as shown in the example of FIG. 2).

In some examples, sublimation onto a glossy and matted outsole plate can utilize a same temperature setting, while using a longer cycle time (or overall duration for sublimation) for the matted plate (since it may require a longer amount of time to transfer the graphic to the matted plate).

In some examples, a hardness of the material of the outsole or outsole plate can alter the sublimation parameters. For example, a material with a higher hardness (such as a fiberglass reinforced polyamide) can be easier to sublimate (transfer the graphic to via sublimation) than a material with a lower hardness (such as Pebax). Thus, in some instances, a temperature and/or cycle time for sublimating onto the outsole or outsole plate can increase as the hardness of the material of the outsole or outsole plate decreases.

In some examples, the vacuum sublimation variables can be interrelated. For example, a longer set duration of time for vacuum sublimation can result in an increase in temperature for the vacuum sublimation process.

In some examples, the selected temperature setting for sublimation at 316 can be in a range of 110° C. to 140° ° C.

In some examples, the selected pressure for sublimation at 316 can be in a range of −0.09-−0.11 MPa or −0.1 MPa.

In some examples, the selected time duration or cycle time for sublimation at 316 can be in a range of 300-500 seconds.

In some examples, the specified temperature, pressure, and/or cycle times within these ranges can be selected based on the graphic on the film (e.g., solid color vs. pattern), the texture of the outsole plate (e.g., matted vs. glossy), the height difference of the cleats (or studs) on the outsole plate, and/or the material of the outsole plate.

In some examples, activating the vacuum-sublimation oven can include activating a button, switch, lever, or the like on the oven, such as a start button 540 on the control panel 538 (FIG. 14). In response to activating the vacuum-sublimation oven, the oven can pressurize to the specified pressure setting (which may include creating a vacuum to a specified negative pressure) and/or heat to a specified temperature for a specified duration of time, thereby causing the dye from the graphic on the printed fill to transfer (adhere or penetrate) to the outsole plates.

For example, as shown in FIGS. 15 and 20, after completing the vacuum sublimation process at 316, a user can remove the tray-outsole-film assembly from the oven to reveal the printed film suctioned to the outsole plates with the dye from the graphic transferred to the outsole plates. Specifically, as shown in FIG. 20, the second graphic 204 (e.g., the dye) from the printed film 600 is transferred to and across the ground-facing surface 216 of the outsole plates 200, including over the cleat members 208. FIG. 21 shows the frame 532 being removed from the tray 528 in preparation for removing the film from the graphic sublimated outsole plates 620.

Similarly, as shown in FIG. 15, the first graphic 202 from the printed film 500 is transferred to and across the ground-facing surface 216 of the outsole plates 200, including over the cleat members 208. In FIG. 15, the frame 532 is removed from the tray 528 to reveal the printed film 500 suctioned to the outsole plates 200.

At 318, method 300 includes removing the film from the outsole plates to reveal the graphic sublimated outsole plates. For example, the film (such as the film 500 in FIG. 15) can be removed (e.g., via pulling) from the outsole plates 200, thereby revealing graphic sublimated outsole plates (e.g., graphic sublimated outsole plates 542 shown in FIG. 16). The graphic sublimated outsole plates 542 include the first graphic 202 formed permanently thereon (and similarly the graphic sublimated outsole plates 620 include the second graphic 204 formed permanently thereon).

The method at 318 can further include removing the covering element (e.g., tape 520) from the graphic sublimated outsole plates 542.

In this way, a graphic can be formed on an outsole for an article of footwear, particularly an outsole or outsole plate that comprises a plurality of cleat members that protrude outward from a base surface of the outsole or outsole plate. By employing a vacuum-sublimation system and method that subjects the outsole or outsole plate, which is disposed within a tray with a printed film sealed over the outsole or outsole plate, to a pre-determined vacuum pressure and temperature for a pre-determined duration of time, a graphic from the printed film can be transferred to the surface of the outsole or outsole plate, including over and around cleat members with varying heights, without tearing.

Exemplary Control Systems and Computing Systems

As discussed above, the methods for forming a graphic on an outsole or outsole plate for an article of footwear can result in a variety of graphics (with different patterns, colors, graphic elements, or the like) to be formed on a ground-facing surface of an outsole or outsole plate. In some examples, some of the methods for forming the graphic on the outsole or outsole plate may be implemented with a computing system, in conjunction with inputs from a user. For example, as described above with reference to FIG. 3, the graphic can be prepared (e.g., created) and printed onto a film using a computing system.

FIG. 6 depicts a generalized example of a suitable computing system 402 in which a portion the above-described innovations may be implemented. The computing system 402 is not intended to suggest any limitation as to scope of use or functionality, as the innovations may be implemented in diverse general-purpose or special-purpose computing systems. For example, the computing system 402 can be used to implement hardware and software.

With reference to FIG. 6, the computing system 402 includes one or more processing units 420, 422, non-volatile memory 424, and memory 426. In FIG. 6, this basic configuration of a computing environment 428 is included within a dashed line. The processing units 420, 422 execute computer-executable instructions, including instructions for forming a graphic for a specified outsole or outsole plate, as disclosed herein (e.g., as described above with reference to FIG. 4). A processing unit can be a general-purpose central processing unit (“CPU”), processor in an application-specific integrated circuit (“ASIC”), or any other type of processor. In a multi-processing system, multiple processing units execute computer-executable instructions to increase processing power. For example, FIG. 6 shows a central processing unit 420 as well as a graphics processing unit (“GPU”) or co-processing unit 422. The tangible memory 426 may be volatile memory (e.g., registers, cache, RAM), non-volatile memory (e.g., ROM, EEPROM, flash memory, etc.), or some combination of the two, accessible by the processing unit(s). The memory 426 stores software 430 implementing one or more innovations described herein, in the form of computer-executable instructions suitable for execution by the processing unit(s).

A computing system may have additional features. For example, the computing system 402 includes storage 432, one or more input devices 434, one or more output devices 436, and one or more communication connections 438. An interconnection mechanism (not shown) such as a bus, controller, or network interconnects the components of the computing system 402. Typically, operating system software (not shown) provides an operating environment for other software executing in the computing system 402, and coordinates activities of the components of the computing system 402.

The tangible storage 432 may be removable or non-removable, and includes magnetic disks, magnetic tapes or cassettes, CD-ROMs, DVDs, or any other medium which can be used to store information and which can be accessed within the computing system 402. The storage 432 stores instructions for the software 430 for implementing one or more innovations described herein.

The input device(s) 434 may be a touch input device such as a keyboard or other devices that provides input to the computing system 402 (e.g., a mouse or imaging device). For video encoding, the input device(s) 434 may be a camera with an image sensor, video card, TV tuner card, or similar device that accepts video input in analog or digital form, or a CD-ROM, CD-RW, DVD, or Blu-Ray that reads video samples into the computing system 402. In some examples, imaging devices capable of capturing image information (e.g., image information for the creation of different graphics, such as the first and second graphics shown in FIGS. 2 and 3) may convert captured, optical images into information transmitted via electrical signals to the computing system. Upon receiving these electrical signals, the one or more processors 420, 422 of the computing system can use this information to create a variety of graphics with different patterns, color schemes, and/or arrangements on a space for the specified outsole or outsole plate.

The output device(s) 436 may be any device that receives an output or that is controlled by the computing system 402 by instructions, or a series of instructions, from the computing system 402 (such as a printing system or printer, such as the printer 404 in FIG. 5). In some examples, the output device(s) 436 could also include the heater 408 and/or the sublimation oven 412 of FIG. 5, wherein the heater 408 and sublimation oven 412 are controlled via signals received from the computing system 402 (rather than being manually controlled by a user).

The communication connection(s) 438 enable communication over a communication medium (e.g., a connecting network) to another computing entity. The communication medium conveys information such as computer-executable instructions, compressed graphics information, video, or other data in a modulated data signal. The communication connection(s) 438 are not limited to wired connections (e.g., megabit or gigabit Ethernet, Infiniband, Fibre Channel over electrical or fiber optic connections) but also include wireless technologies (e.g., RF connections via Bluetooth, WiFi (IEEE 802.11a/b/n), WiMax, cellular, satellite, laser, infrared) and other suitable communication connections for providing a network connection for the disclosed agents, bridges, and agent data consumers. In a virtual host environment, the communication(s) connections can be a virtualized network connection provided by the virtual host.

Some examples of the disclosed methods can be performed using computer-executable instructions implementing all or a portion of the disclosed technology in a computing cloud 440. For example, disclosed computer-readable instructions can be executed by processors located in the computing environment 428, or the disclosed computer-readable instructions can be executed on servers located in the computing cloud 440.

Computer-readable media are any available media that can be accessed within a computing environment 428. By way of example, and not limitation, with the computing environment 428, computer-readable media include memory 424 and/or storage 431. As should be readily understood, the term computer-readable storage media includes the media for data storage such as memory 424 and storage 432, but does not include transmission media such as modulated data signals or other transitory signals.

The innovations can be described in the general context of computer-executable instructions, such as those included in program modules, being executed in a computing system on a target real or virtual processor. Generally, program modules include routines, programs, libraries, objects, classes, components, data structures, etc. that perform particular tasks or implement particular data types. The functionality of the program modules may be combined or split between program modules as desired in various examples. Computer-executable instructions for program modules may be executed within a local or distributed computing system.

Additional Examples of the Disclosed Technology

Additional examples of the disclosed technology are enumerated below.

Example 1. A method for forming a graphic on an outsole for an article of footwear, comprising: preparing an outsole plate for the outsole for graphic sublimation, the outsole plate comprising a plurality of cleat members that protrude outwardly from a base surface of the outsole plate, and mounting the outsole plate within a tray; positioning a printed film comprising a graphic over the outsole plate and the tray to form a tray assembly and positioning the tray assembly inside a vacuum-sublimation oven; selecting a pressure, temperature, and duration for transferring the graphic on the printed film to the outsole plate based on each of a type of graphic on the printed film, a texture of the outsole plate, a height difference of the cleat members on the outsole plate, and a material of the outsole plate; and activating the vacuum-sublimation oven to transfer the graphic on the printed film to the outsole plate at the selected pressure, temperature, and duration such that the graphic is formed over at least a first portion of the base surface and cleat members protruding from the first portion of the base surface.

Example 2. The method of any example herein, particularly example 1, wherein the preparing the outsole plate includes pre-heating the outsole plate.

Example 3. The method of any example herein, particularly example 2, further comprising, following pre-heating the outsole plate, cleaning the outsole plate and pre-heating the cleaned outsole plate prior to mounting the outsole plate within the tray.

Example 4. The method of any example herein, particularly any one of examples 1-3, further comprising masking the outsole plate by covering a second portion of the base surface and cleat members protruding from the second portion of the base surface with a covering element, prior to mounting the outsole plate within the tray, and further comprising, after transferring the graphic on the printed film to the outsole plate, removing the printed film and the covering element to reveal the graphic formed over the first portion of the base surface and the cleat members protruding therefrom and not on the second portion of the base surface and the cleat members protruding therefrom.

Example 5. The method of any example herein, particularly any one of examples 1-4, wherein mounting the outsole plate within the tray includes mounting the outsole plate onto an outsole-mounting portion of the tray, and wherein positioning the printed film includes sealing the printed film to the tray, over the outsole plate, with a sealing element.

Example 6. The method of any example herein, particularly any one of examples 1-5, wherein the selected pressure is a negative pressure which creates a vacuum.

Example 7. The method of any example herein, particularly example 6, wherein the selected pressure is −0.1 MPa.

Example 8. The method of any example herein, particularly any one of examples 1-7, wherein the selected temperature is in a range of 110 to 140 degree Celsius and the selected duration is in a range of 300 to 500 seconds.

Example 9. The method of any example herein, particularly any one of examples 1-8, wherein selecting the pressure, temperature and duration based on the type of graphic on the printed film includes selecting a higher temperature and longer duration when the graphic is a solid color graphic as opposed to a patterned graphic and selecting a lower temperature and shorter duration when the graphic is the patterned graphic as opposed to the solid color graphic.

Example 10. The method of any example herein, particularly any one of examples 1-9, wherein selecting the pressure, temperature and duration based on the texture of the outsole plate includes selecting a longer duration when the outsole plate is matted as opposed to glossy and selecting a shorter duration when the outsole plate is glossy as opposed to matted.

Example 11. The method of any example herein, particularly any one of examples 1-10, wherein selecting the pressure, temperature and duration based on the height difference of the cleat members on the outsole plate includes selecting one or more of a higher temperature and longer duration as a vertical height difference between two or more cleat members of the plurality of cleat members on the outsole plate increases.

Example 12. The method of any example herein, particularly any one of examples 1-11, wherein selecting the pressure, temperature and duration based on the material of the outsole plate includes selecting one or more of a higher temperature and longer duration as a hardness of the material of the outsole plate decreases.

Example 13. The method of any example herein, particularly any one of examples 1-12, wherein the cleat members of the plurality of cleat members have a vertical height in a range of 40-80 mm.

Example 14. The method of any example herein, particularly example 13, wherein the plurality of cleat members includes at least two cleat members having a different height.

Example 15. The method of any example herein, particularly any one of examples 1-14, wherein the plurality of cleat members includes at least two cleat members having a different shape.

Example 16. A method for forming a graphic on an outsole for an article of footwear, comprising: preparing an outsole plate for the outsole for graphic sublimation, the outsole plate comprising a plurality of cleat members that protrude outwardly from a base surface of the outsole plate, and mounting the outsole plate within a tray; positioning a printed film comprising a graphic over the outsole plate and the tray to form a tray assembly and positioning the tray assembly inside a vacuum-sublimation oven; selecting a temperature from within a range of 110 to 140 degrees Celsius and a cycle time from within a range of 300 to 500 seconds for transferring the graphic on the printed film to the outsole plate; and activating the vacuum-sublimation oven to transfer the graphic on the printed film to the outsole plate at the selected temperature and cycle time, and at a pressure of −0.1 MPa such that the graphic is formed over at least a first portion of the base surface and the plurality of cleat members.

Example 17. The method of any example herein, particularly example 16, wherein selecting the temperature and cycle time includes selecting a higher temperature and longer cycle time for a solid color graphic and selecting a lower temperature and shorter cycle time for a patterned graphic.

Example 18. The method of any example herein, particularly either example 16 or example 17, wherein selecting the temperature and cycle time includes selecting a longer cycle time and first temperature within the range when the outsole plate is matted and selecting a shorter cycle time and the first temperature when the outsole plate is glossy.

Example 19. The method of any example herein, particularly any one of examples 16-18, wherein selecting the temperature and cycle time includes selecting one or more of a higher temperature and longer cycle time as a vertical height difference between two or more cleat members of the plurality of cleat members on the outsole plate increases.

Example 20. The method of any example herein, particularly any one of examples 16-19, wherein selecting the temperature and cycle time includes selecting one or more of a higher temperature and longer cycle time as a hardness of a material of the outsole plate decreases.

Example 21. The method of any example herein, particularly any one of examples 16-20, wherein the plurality of cleat members includes at least two cleat members having a different height within a range of 40-80 mm.

Example 22. The method of any example herein, particularly any one of examples 16-21, wherein the preparing the outsole plate includes pre-heating the outsole plate within a heater at a predetermined temperature for a predetermined amount of time.

Example 23. The method of any example herein, particularly example 22, further comprising, following pre-heating the outsole plate, cleaning the outsole plate and pre-heating the cleaned outsole plate prior to mounting the outsole plate within the tray.

Example 24. The method of any example herein, particularly any one of examples 16-23, further comprising masking the outsole plate by covering a second portion of the base surface and the plurality of cleat members with a covering element, prior to mounting the outsole plate within the tray, and further comprising, after transferring the graphic on the printed film to the outsole plate, removing the printed film and then the covering element to reveal the graphic formed over the first portion of the base surface and the cleat members and not on the second portion of the base surface and the cleat members.

Example 25. The method of any example herein, particularly any one of examples 16-24, wherein mounting the outsole plate within the tray includes mounting the outsole plate onto a jig of the tray, the jig shaped to receive an inner surface of the outsole plate that is disposed opposite the base surface, and wherein positioning the printed film includes sealing the printed film to a rim of the tray, over the outsole plate, with a sealing element.

Example 26. A vacuum-sublimation system comprising: a tray comprising an outsole-mounting portion and a rim disposed above the outsole-mounting portion, wherein the outsole-mounting portion is shaped to receive an outsole plate comprising a plurality of cleat members thereon; a frame configured to fit and seal against the rim; and a vacuum-sublimation oven comprising a drawer configured to receive the tray therein and one or more controls for setting a pressure, temperature, and time duration for vacuum-sublimation.

Example 27. The vacuum-sublimation system of any example herein, particularly example 26, wherein the outsole-mounting portion is shaped to receive an inner surface of the outsole plate which is opposite a ground-facing surface of the outsole plate, the ground-facing surface including the plurality of cleat members.

Example 28. The vacuum-sublimation system of any example herein, particularly either example 26 or example 27, wherein the rim is configured to receive a printed film comprising a graphic to be sublimated onto the outsole plate thereon, and wherein the frame is configured to fit and seal against the rim, thereby sandwiching edges of the printed film between the rim and the frame.

Example 29. The vacuum-sublimation system of any example herein, particularly any one of examples 26-28, further comprising a heater configured to receive an outsole plate and heat the outsole plate to a predetermined temperature for a predetermined amount of time.

Example 30. A method for forming a graphic on an outsole for an article of footwear, comprising: preparing an outsole plate for the outsole for graphic sublimation, the outsole plate comprising a plurality of cleat members that protrude outwardly from a base surface of the outsole plate, and mounting the outsole plate within a tray; positioning a printed film comprising a graphic over the outsole plate and the tray to form a tray assembly and positioning the tray assembly inside a vacuum-sublimation oven; selecting one or more of a pressure, temperature, and duration for transferring the graphic on the printed film to the outsole plate based on at least one of a type of graphic on the printed film, a texture of the outsole plate, a height difference of the cleat members on the outsole plate, and a material of the outsole plate; and activating the vacuum-sublimation oven to transfer the graphic on the printed film to the outsole plate at the selected pressure, temperature, and duration such that the graphic is formed over at least a first portion of the base surface and cleat members protruding from the first portion of the base surface.

Example 31. The method of any example herein, particularly example 30, wherein the selecting one or more of the pressure, temperature, and duration for transferring the graphic on the printed film to the outsole plate is based on at least two or more of a type of graphic on the printed film, a texture of the outsole plate, a height difference of the cleat members on the outsole plate, and a material of the outsole plate.

Example 32. The method of any example herein, particularly example 30 or 31, wherein the selecting one or more of the pressure, temperature, and duration for transferring the graphic on the printed film to the outsole plate is based on a height difference of the cleat members on the outsole plate.

In view of the many possible examples to which the principles of the disclosed technology may be applied, it should be recognized that the illustrated examples are only preferred examples of the disclosed technology and should not be taken as limiting the scope of the claimed subject matter. Rather, the scope of the claimed subject matter is defined by the following claims and their equivalents.

Claims

1. A method for forming a graphic on an outsole for an article of footwear, comprising:

preparing an outsole plate for the outsole for graphic sublimation, the outsole plate comprising a plurality of cleat members that protrude outwardly from a base surface of the outsole plate, and mounting the outsole plate within a tray;

positioning a printed film comprising a graphic over the outsole plate and the tray to form a tray assembly and positioning the tray assembly inside a vacuum-sublimation oven;

selecting a pressure, temperature, and duration for transferring the graphic on the printed film to the outsole plate based on each of a type of graphic on the printed film, a texture of the outsole plate, a height difference of the cleat members on the outsole plate, and a material of the outsole plate; and

activating the vacuum-sublimation oven to transfer the graphic on the printed film to the outsole plate at the selected pressure, temperature, and duration such that the graphic is formed over at least a first portion of the base surface and cleat members protruding from the first portion of the base surface.

2. The method of claim 1, wherein the preparing the outsole plate includes pre-heating the outsole plate.

3. The method of claim 2, further comprising, following pre-heating the outsole plate, cleaning the outsole plate and pre-heating the cleaned outsole plate prior to mounting the outsole plate within the tray.

4. The method of claim 1, further comprising masking the outsole plate by covering a second portion of the base surface and cleat members protruding from the second portion of the base surface with a covering element, prior to mounting the outsole plate within the tray, and further comprising, after transferring the graphic on the printed film to the outsole plate, removing the printed film and the covering element to reveal the graphic formed over the first portion of the base surface and the cleat members protruding therefrom and not on the second portion of the base surface and the cleat members protruding therefrom.

5. The method of claim 1, wherein the selected temperature is in a range of 110 to 140 degree Celsius and the selected duration is in a range of 300 to 500 seconds.

6. The method of claim 1, wherein selecting the pressure, temperature and duration based on the type of graphic on the printed film includes selecting a higher temperature and longer duration when the graphic is a solid color graphic as opposed to a patterned graphic and selecting a lower temperature and shorter duration when the graphic is the patterned graphic as opposed to the solid color graphic.

7. The method of claim 1, wherein selecting the pressure, temperature and duration based on the texture of the outsole plate includes selecting a longer duration when the outsole plate is matted as opposed to glossy and selecting a shorter duration when the outsole plate is glossy as opposed to matted.

8. The method of claim 1, wherein selecting the pressure, temperature and duration based on the height difference of the cleat members on the outsole plate includes selecting one or more of a higher temperature and longer duration as a vertical height difference between two or more cleat members of the plurality of cleat members on the outsole plate increases.

9. The method of claim 1, wherein selecting the pressure, temperature and duration based on the material of the outsole plate includes selecting one or more of a higher temperature and longer duration as a hardness of the material of the outsole plate decreases.

10. The method of claim 1, wherein the cleat members of the plurality of cleat members have a vertical height in a range of 40-80 mm.

11. The method of claim 10, wherein the plurality of cleat members includes at least two cleat members having a different height.

12. The method of claim 1, wherein the plurality of cleat members includes at least two cleat members having a different shape.

13. A method for forming a graphic on an outsole for an article of footwear, comprising:

preparing an outsole plate for the outsole for graphic sublimation, the outsole plate comprising a plurality of cleat members that protrude outwardly from a base surface of the outsole plate, and mounting the outsole plate within a tray;

positioning a printed film comprising a graphic over the outsole plate and the tray to form a tray assembly and positioning the tray assembly inside a vacuum-sublimation oven;

selecting a temperature from within a range of 110 to 140 degrees Celsius and a cycle time from within a range of 300 to 500 seconds for transferring the graphic on the printed film to the outsole plate; and

activating the vacuum-sublimation oven to transfer the graphic on the printed film to the outsole plate at the selected temperature and cycle time, and at a pressure of −0.1 MPa such that the graphic is formed over at least a first portion of the base surface and the plurality of cleat members.

14. The method of claim 13, wherein selecting the temperature and cycle time includes selecting a higher temperature and longer cycle time for a solid color graphic and selecting a lower temperature and shorter cycle time for a patterned graphic.

15. The method of claim 13, wherein selecting the temperature and cycle time includes selecting a longer cycle time and first temperature within the range when the outsole plate is matted and selecting a shorter cycle time and the first temperature when the outsole plate is glossy.

16. The method of claim 13, wherein selecting the temperature and cycle time includes selecting one or more of a higher temperature and longer cycle time as a vertical height difference between two or more cleat members of the plurality of cleat members on the outsole plate increases.

17. The method of claim 13, wherein selecting the temperature and cycle time includes selecting one or more of a higher temperature and longer cycle time as a hardness of a material of the outsole plate decreases.

18. The method of claim 13, wherein the plurality of cleat members includes at least two cleat members having a different height within a range of 40-80 mm.

19. A vacuum-sublimation system comprising:

a tray comprising an outsole-mounting portion and a rim disposed above the outsole-mounting portion, wherein the outsole-mounting portion is shaped to receive an outsole plate comprising a plurality of cleat members thereon;

a frame configured to fit and seal against the rim; and

a vacuum-sublimation oven comprising a drawer configured to receive the tray therein and one or more controls for setting a pressure, temperature, and time duration for vacuum-sublimation.

20. The vacuum-sublimation system of claim 19, wherein the rim is configured to receive a printed film comprising a graphic to be sublimated onto the outsole plate thereon, and wherein the frame is configured to fit and seal against the rim, thereby sandwiching edges of the printed film between the rim and the frame.